Copolyamide powder and its preparation, use of copolyamide powder in a shaping process and mouldings produced from this copolyamide powder

Abstract

A task often encountered in very recent times is the rapid provision of prototypes. Particularly suitable processes are those based on pulverulent materials and in which the desired structures are produced layer-by-layer through selective melting and solidification. The invention provides the constitution, production and use of a copolyamide powder which was produced using the following monomer units: a) laurolactam or ω-aminoundecanoic acid, and also b) dodecanedioic acid, and either c) decanediamine or dodecanediamine, in shaping processes, and also to mouldings produced through a layer-by-layer process which selectively melts regions of a powder layer, using this specific powder. Once the regions previously melted layer-by-layer have been cooled and solidified, the moulding can be removed from the powder bed. The mouldless layer-by-layer processes for the production of components using the copolyamide powder result in simplified and more reliable conduct of the process and better recyclability.

Description

FIELD OF THE INVENTION[0001]A task often encountered in very recent times is the rapid provision of prototypes. Particularly suitable processes are those based on pulverulent materials and in which the desired structures are produced layer-by-layer through selective melting and solidification. Support structures for overhangs and undercuts can be omitted here, since the powder bed surrounding the molten regions provides sufficient support. The subsequent work needed to remove supports is likewise no longer needed. The processes are also suitable for short-run production.DISCUSSION OF THE BACKGROUND[0002]The present invention relates to the constitution, production and use of a copolyamide powder which was produced using the following monomer units:[0003]laurolactam or ω-aminoundecanoic acid, and either[0004]dodecanedioic acid or sebacic acid, and either[0005]decanediamine or dodecanediamine,in shaping processes, and also to mouldings produced through a layer-by-layer process which s...

AI Technical Summary

Problems solved by technology

One problem that has to be solved when polymer powder is processed in a mouldless process is that, to avoid what is known as curl, the temperature in the construction chamber has to be maintained with maximum uniformity at a level just below the melting point of the polymeric material.

This produces a risk that when the next powder layer is applied, for example via a doctor or a roll, the protruding regions will be displaced or even pulled away completely.

An intrinsic feature of semicrystalline thermoplastics which is difficult to control in many instances is their crystallinity, or the resultant volume change during cooling of the melt.

Although the volume change caused by crystallinity in a single layer can substantially be compensated by using a very complicated and precise temperature profile, the volume change resulting from crystallization in three-dimensional mouldings of any desired structure is non-uniform across the moulding.

In terms of processing reliability, another disadvantage of the commercially available and most widely used homopolyamide, nylon-12 powder, is a relatively high BET surface area in comparison with ground powder or powder obtained by polymerization in solution.

The high BET surface area leads to impaired powder flowability, and although this can be countered by addition of a suitable powder-flow aid, this is achieved at the cost of decreased processing latitude, and the result, less reliable processes, is rather counterproductive for rapid manufacturing.

The high BET surface area also has a disadvantageous effect on the warpage of the components.

Powders obtained by milling with low BET surface area, for example nylon-11, wh...